Compact and maintainable waste reformation apparatus

ABSTRACT

Methods and apparatus for compact and easily maintainable waste reformation. Some embodiments include a rotary oven reformer adapted and configured to provide synthesis gas from organic waste. Some embodiments include a rotary oven with simplified operation both as to reformation of the waste, usage of the synthesized gas and other products, and easy removal of the finished waste products, preferably in a unit of compact size for use in austere settings. Yet other embodiments include Fischer-Tropsch reactors of synthesized gas. Some of these reactors include heat exchanging assemblies that provide self-cleaning effects, efficient utilization of waste heat, and ease of cleaning.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority as a continuation ofU.S. patent application Ser. No. 16/918,058, filed Jul. 1, 2020, whichclaims the benefit of priority as a continuation of U.S. patentapplication Ser. No. 15/514,041, filed Mar. 27, 2017, which claims thebenefit of priority as a 371 filing of International Application No.PCT/US2015/051962, filed Sep. 24, 2015, entitled COMPACT ANDMAINTAINABLE WASTE REFORMATION APPARATUS, which claims the benefit ofpriority to U.S. Provisional Patent Application Ser. No. 62/054,524,filed Sep. 24, 2014, entitled ROTARY OVEN REFORMER, and U.S. ProvisionalPatent Application Ser. No. 62/174,823, filed Jun. 12, 2015, entitledIMPROVED FISCHER-TROPSCH REACTOR, all of which are incorporated hereinby reference.

FIELD OF THE INVENTION

Various embodiments pertain to systems for converting waste to fueland/or energy, and in particular to such systems that are of compactsize for operation at remote locations, and in particular to other suchsystems that produce Fischer-Tropsch products with reactors that areeasily maintained.

BACKGROUND OF THE INVENTION

There is an urgent need at military-forward operating bases (FOB) forboth: (a) disposal of waste; and (b) generation of electricity.Currently, the waste produced from operations, supply depots,commissaries, cafeterias, medical facilities, etc is being simply burnedin open pits. This practice exposes the troops and military supportpersonnel to toxics, pathogens, etc., provides a very clear infra-redsignature, and leaves environmental problem trails. Hauling the wasteout from the FOBs with long truck convoys exposes troops and truckoperators to being attacked. The record here is horrible with morepersonnel being lost in the waste hauling operations than at the frontlines. Also hauling in fuel to run generators to recharge the myriad ofbatteries used for the advanced instrumentation and communicationsassets has a similar convoy death record.

Domestically, there are problems from waste disposal as well inunderdeveloped regions, stressed urban areas, and very remote areas ofoil and gas exploration and production operations, medical facilities,emergency cleanup, etc. as well.

What is needed is a small portable module that can be air dropped ortrucked in that will use these waste streams to produce electric power.Various embodiments of the present invention address these needs.

The synthetic production of hydrocarbons by the catalytic reaction ofcarbon monoxide and hydrogen is well known and generally referred to asthe Fischer-Tropsch (FT) reaction. The FT process was developed in theearly 1920's in Germany. It has been commercial since World War II,particularly in South Africa. The FT reaction benefits from a catalystto convert the carbon monoxide (CO) and hydrogen (H₂) to a range ofparaffinic hydrocarbons from 1 to 100 carbons.

Numerous types of reactor systems have been used for carrying out FTsynthesis ranging from fixed bed three phase bubble column designs,fluidized bed, ebullating beds, and fixed plate heat exchangers. Thesevarious designs may encounter high expense due to large amounts ofcatalyst used from inefficient contact with the catalyst surface, andineffective cooling.

Fixed bed reactors of individual catalyst particles ae packed into tubesarranged in a cylindrical vessel. The individual particles can involvevarious shapes of spheres, cylinders, saddles, and rings with voidvolume fractions from 0.3 the 0.5. Although these packed bed reactorsare simple and can be scaled up, they encounter high heat releaserequirements with the tube size being small with high pressure drop.Also, these narrow tubes are difficult to clean and maintain.

The manufacture of finned tubes for heat exchangers is used in somedesigns. Modern extrusion technology can produce tubes with a widevariety of cross-sections and alloys.

Some FT reactors include a tube packed with extended surface materials(I.e. Beryl saddles, etc.) which are coated with the catalyst. Thesyngas flows inside the tube while the coolant flows on the outside ofthe tube. The tube internal diameter should be more than 3 inches toradially extract the heat, and the packing should be small size to avoida wall affect, but a small packing size can produce pressure drops. Sothe reactor may not efficient from the ratio of surface area to volumestandpoint. There is also the challenge that at the contact points theFT liquids can gather and form hard paraffin wax resin blockages whichcan require the bed to being cleaned or replaced often. Another approachis to use a larger tube and irrigate the column of pack catalyst pelletswith the FT liquid or a solvent to carry the heat away from the catalystpacking—such a reactor is termed “trickle phase”. This benefits from auniform distribution of liquid to avoid hotspots and running the risk offorming resin blockages which create further hotspots and sometimescause reactor run away.

Plate heat exchangers had been used with narrow spacing between theplates, in which the plates are coated with a catalyst. This conceptachieves a large amount of catalyst surface area in a large reactor thatis heat exchanged with the cooling liquid on the other side of theplates; thus, it is not volume efficient and thus expensive tofabricate. There are many variations of the concept of closely spacedplates that are catalyst coated to develop a plate array or matrix heatexchanger, but they can encounter narrow spacing, high pressure drop,flow obstruction and high cost of manufacture.

A more recent design uses commercial air conditioner cores to help cutthe cost of manufacture, avoid narrow spacing, and provide a largeamount of surface area, but these cores have to be stacked and placedinside of a large reactor vessel and then individually plumbed to theoutside. This makes it a complex reactor assembly, a challenge to scale,difficult to maintain, and difficult to clean. And stacked cores have acomplex FT liquid downflow around the heat exchange tubing passingthrough the fins that risks the formation of resin blockages at junctionpoints. Unless the cores are custom manufactured to be large, thereactor does not easily scale up from a small pilot scale to a largecommercial scale. This added stacked core complexity makes themaintenance even more challenging.

What is needed are new designs of FT reactors that overcome some of thepast problems, and which present novel and non-obvious improvements tothe FT process.

SUMMARY OF THE INVENTION

One embodiment relates to an improved rotary oven reformer that useselectric heat to carry out gas-phase steam/CO2 reforming in a smallmodular size that can be placed in the field or in an apartment as wellas in a medical clinic or small hospital. The rotary oven in oneembodiment has the shape of a concrete mixer with the non-rotatingheating cartridge at its center and spiral flights around the inside.The central heating cartridge provides the electric heat which heats thesteam and CO2 entering the rotary oven and further heats the exit syngas(preferably with the addition of more steam) to complete the reaction todestroy the organic material.

Another embodiment includes the internal spiral flight assembly havingtwo purposes: one to rip apart the garbage bags by its sharpened,tooth-like edges and agitate the material to get good contacting forcompleting the chemistry while rotating in one direction and the secondpurpose is to remove any solid material at the end of the process cyclewhile rotating in the other direction at much higher speed. In onedirection of rotation the edges of the teeth are angled toward theorganic material and penetrate the organic material. In the otherdirection of rotation the spiral shape of the overall tooth patterncombined (presenting a spiral wall from the body of the teeth) presentsa pathway that guides the rotating burned ashes toward the door of theoven.

Another embodiment includes the use of a second door that uses a scoopand a hopper to help remove the solids at the end of the process cycle.Near the end of the process cycle when the cooling cycle is nearlycomplete, the first door is open (which was closed during hightemperature reformation) and the second door is closed. The left handdoor which inserts the scoop and hopper into the interior of the drumoven for removal of smaller solids including broken glass. The largestsolids such as larger sized cans and metal lids may not go down thehopper but stay in the drum and can be manually removed separately whichencourages recycling of the scrap metals.

Yet another embodiment includes a woven ceramic cloth sock arrangedoutside the heated cartridge to remove any particulate material to keepit out of the exit syngas. This sock filter has its impacted soliddeposits removed by the internal turbulence, vibration, and fallingmaterials from the rotating drum. If the sock filter deposits becomeexcessive after running many process cycles, the sock can be removed andreplaced with a fresh one.

A further embodiment includes the use of the small sized solid oxidefuel-cell or other, preferably high temperature fuel-cell to use thegenerated syngas to produce both high temperature heat to heat therotary oven as well as electricity to drive the process.

Yet a further embodiment includes an array of electric heaters radiatingthermal energy onto the outside of the rotating oven to help evaporatemoisture, heat the solids, and help the chemistry reactions completefaster.

Another embodiment includes made possible by the features enumeratedabove which allow the rotary oven reformer drum and the supportingprocess units and their controls to be small enough to permit the moduleto be a small portable size, such as 7 feet wide, 6 feet deep, and 7feet tall in one example.

It is one aspect of some embodiments of the present invention to providea design for a FT reactor using common finned tubes coated with catalystin which the finned tubes can be removed individually for maintenance.In some embodiments, the gas flow in the reactor is countercurrent tothe flow of FT liquid on the exterior of the fins. The FT liquid thusformed flows downward in the channels established by the fins and dripsoff of the tube fins unobstructed to avoid the formation of resinblockage. Further, the FT liquid removal has adequate volume fordisengaging the froth and foam from the exit unconverted syngas thatmoves upward through the reactor.

Yet another aspect of some embodiments pertains to an FT reactor designusing catalyst coated finned tubes placed in a pressure vessel such thatthe individual tubes can be removed for cleaning and maintenance. Stillfurther alternative aspects of such a reactor design include one or moreof the following, in any combination:

-   -   The FT reactor design wherein the pressure vessel is a        cylindrical vessel with a flange top plate.    -   The FT reactor design wherein the individual tubes can be        removed while keeping the reactor inerted, eliminating the need        to reactivate the catalyst.    -   The FT reactor design wherein the falling FT liquid experiences        an increase in finned tube temperature as it falls to the bottom        of the reactor.    -   The FT reactor design wherein the syngas moving upward in the        vessel is countercurrent to the down-flowing FT liquid.    -   The FT reactor design wherein the FT liquid leaves the bottom of        the reactor spaced apart from the syngas exit port at the top of        the reactor to assure complete disengagement of the gas from the        liquid without the liquid being entrained in the syngas exit.    -   The FT reactor design wherein the externally-finned heat        exchangers are adapted and configured to be substantially free        of obstructions or create spots of long residence time with        objectionable formation of resin blockages by the falling FT        liquid.    -   The FT reactor design wherein the falling FT liquid fluid flow        minimizes the formation of undesirable heavy paraffin wax.    -   The FT reactor design wherein the finned tube has a cylindrical        cross section.    -   The FT reactor design wherein the finned tube has a generally        hexagonal cross sectional shape.

It will be appreciated that the various apparatus and methods describedin this summary section, as well as elsewhere in this application, canbe expressed as a large number of different combinations andsubcombinations. All such useful, novel, and inventive combinations andsubcombinations are contemplated herein, it being recognized that theexplicit expression of each of these combinations is unnecessary.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the figures shown herein may include dimensions. Further, someof the figures shown herein may have been created from scaled drawingsor from photographs that are scalable. It is understood that suchdimensions, or the relative scaling within a figure, are by way ofexample, and not to be construed as limiting.

FIG. 1 is a schematic representation of a rotating oven according to oneembodiment of the present invention.

FIG. 2 is a schematic arrangement of a portion of an apparatus accordingto one embodiment of the present invention.

FIG. 3 is a schematic representation of another embodiment of thepresent invention.

FIG. 4 is a process flow diagram according to one embodiment of thepresent invention.

FIG. 5 is a schematic representation of a toothed-spiral flightaccording to one embodiment of the present invention.

FIG. 6 shows a schematic, cross-sectional representation of a singlecatalyst-coated finned tube with all connections at the top by flexibletubing, according to one embodiment of the present invention.

FIG. 7 shows a cross sectional representation of catalyst-coated finnedtubes arranged in the reactor vessel lid, according to anotherembodiment of the present invention.

FIG. 8 is a schematic representation of the apparatus of FIG. 7 lookingdown, which is a reactor design with finned tubes supplied from insidereactor.

FIG. 9 is a schematic representation of a process and instrumentationdiagram for an FT skid interfacing to catalyst coated finned tubesaccording to one embodiment of the present invention.

FIG. 10 is a schematic representation of a process according to anotherembodiment of the present invention.

FIG. 11 is a schematic representation of a portion of a processaccording to another embodiment of the present invention, this portionbeing functionally associated with the portions of the same processshown in FIGS. 12 and 13 .

FIG. 12 is a schematic representation of a portion of a processaccording to another embodiment of the present invention, this portionbeing functionally associated with the portions of the same processshown in FIGS. 11 and 13 .

FIG. 13 is a schematic representation of a portion of a processaccording to another embodiment of the present invention, this portionbeing functionally associated with the portions of the same processshown in FIGS. 11 and 12 .

ELEMENT NUMBERING

The following is a list of element numbers and at least one noun used todescribe that element. It is understood that none of the embodimentsdisclosed herein are limited to these nouns, and these element numberscan further include other words that would be understood by a person ofordinary skill reading and reviewing this disclosure in its entirety.These element numbers refer to FIGS. 1, 2, 3, and 4 .

2 ROR 12 ROR drum 14 spiral vanes 15 tooth 16 rollers 18 door seal 20crude syngas 22 front opening 22 CO₂ inlet 24 cartridge 25 volatile gasfrom waste 26 filter sock 28 gas port, heat exchanger 30 solids 32 drumoven opening 34 oven heating rods 36 hinges 38 handle 40 purge gas inlet42 left-hand door 46 insulating layer 48 hopper 50 scoop 52 exit 54purge and cooling gas inlet 60 rotary seal 61 pump 62 door 63 batterybank 64 lock 65 fuel cell 66 control 68 control 70 control screen 72reforming reactor 73 high purity syngas 74 heat exchanger 75 heatexchanger outlet 76 catalytic converter 77 exit gas 78 sorbent bed 79clean gases 80 exhaust pipe, stream 81 stream 82 power 83 stream 88 tank89 fuel 90 ambient exhaust port 92 cabinet 93 steam 94 rotary vacuumpump 95 fuel cell heat output 96 rotary vacuum pump 97 pumped recyclegas 98 power 99 exchanger heat output

Element Numbering

The following is a list of element numbers and at least one noun used todescribe that element. It is understood that none of the embodimentsdisclosed herein are limited to these nouns, and these element numberscan further include other words that would be understood by a person ofordinary skill reading and reviewing this disclosure in its entirety.These element numbers refer to FIGS. 6 to 10 .

204 cooling-tube assembly 208 catalyst coated fins 209 coolant supplypassage 210 external tube 211 closed end 212 top flange 214 sanitaryunion 216 thermal fluid 218 tee 220 center tube 222 vapor-liquid exits;steam 227 inlet 276 heater 228 steam tubes; internal tube 278 pump 230syngas; entry 232 reactor; vessel 234 port; exit 236 steel tubing 237cooling media manifold; plenum 238 tube ring manifold; assembly 240locking nut 242 tube 244 threads 246 ledge; dome 248 flange 250 coolantsupply port 252 port 254 port 256 inspection port 258 port 260 coolantreturn port 270 reactor 272 streams 273 heat exchanging assembly; finnedtubes 275 syngas inlet 279 liquid 281 stream 282 exchanger 288 aircooler 290 steam turbine; line 291 steam trap 292 stream; separator 294stream 298 stream

Element Nomenclature Process Diagram

The following is a list of element numbers and at least one noun used todescribe that element. It is understood that none of the embodimentsdisclosed herein are limited to these nouns, and these element numberscan further include other words that would be understood by a person ofordinary skill reading and reviewing this disclosure in its entirety.This numbering system and nomenclature refers to FIGS. 6 to 10 . It isfurther understood that on those same figures the use ofnon-alphanumeric (i.e., the use of numbers without a letter prefix)refer to product streams being passed from one component to another.

inputs outputs C-11 Compressor 1 atmos 360 psig C-13 Compressor 360 psig400 psig D-23 Stream Divider FT gas/liquid bottom Recycle gas E-32 SteamTurbine-Generator Steam, 260F, 660 psig Steam, 240F, 20 psig F-24 Flashtank/separator Gas/liquid mix Separate gas and liquids F-9 Flashtank/separator Gas/liquid mix Separate gas and liquids H-2 Heating Sideof Heat  88° F.  980° F. Exchanger H-20 Heating Side of Heat 375° F. 650° F. Exchanger H-6 Heating Side of Heat 930° F. 1850° F. ExchangerM-1 Mixer Recycle, steam, Recycle, steam, biomass biomass M-21 Mixersyngas and parafins syngas and parafins M-27 Mixer All water All waterM-31 Mixer CO2 and light ends CO2 and light ends M-33 Mixer 508° F. 508°F. M-5 Mixer Steam, syngas Steam, syngas P-25 Pump water R-19 FT ReactorFinished syngas Liquid hydrocarbons R-3 Equilibrium Reactor biomasssyngas R-7 Equilibrium Reactor Crude syngas Finished syngas S-10Component Splitter Syngas & impurities impurities S-12 ComponentSplitter Wet syngas Water and dry syngas S-22 Component Splitter Lightparaffins wax S-26 Component Splitter Gas and liquid paraffins Separategas/liquid paraffin S-30 Component Splitter Liquid paraffins Dieselproduct S-4 Component Splitter Syngas & solids solids T-17 DistillationTower Mixed paraffins Separated lights and heavy V-18 Valve Pressurecontrol X-14 Gas-to-gas Heat Exchanger Hot syngas Cool syngas X-15 AirCooler Heat Exchanger Hot syngas Cool syngas X-16 Gas-to-gas HeatExchanger Hot paraffins Cool paraffins X-28 Gas-to-gas Heat ExchangerHot paraffins Cool paraffins X-29 Gas-to-gas Heat Exchanger Hotparaffins Cool paraffins X-8 Gas-to-gas Heat Exchanger Hot syngas Coolsyngas

Detailed Description of One or More Embodiments

For the purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, such alterations and furthermodifications in the illustrated devices and processes, and such furtherapplications of the principles of the invention as illustrated thereinbeing contemplated as would normally occur to one skilled in the art towhich the invention relates. At least one embodiment of the presentinvention will be described and shown, and this application may showand/or describe other embodiments of the present invention, and furtherpermits the reasonable and logical inference of still other embodimentsas would be understood by persons of ordinary skill in the art.

It is understood that any reference to “the invention” is a reference toan embodiment of a family of inventions, with no single embodimentincluding an apparatus, process, or composition that should be includedin all embodiments, unless otherwise stated. Further, although there maybe discussion with regards to “advantages” provided by some embodimentsof the present invention, it is understood that yet other embodimentsmay not include those same advantages, or may include yet differentadvantages. Any advantages described herein are not to be construed aslimiting to any of the claims. The usage of words indicating preference,such as “preferably,” refers to features and aspects that are present inat least one embodiment, but which are optional for some embodiments.

Although various specific quantities (spatial dimensions, temperatures,pressures, times, force, resistance, current, voltage, concentrations,wavelengths, frequencies, heat transfer coefficients, dimensionlessparameters, etc.) may be stated herein, such specific quantities arepresented as examples only, and further, unless otherwise explicitlynoted, are approximate values, and should be considered as if the word“about” prefaced each quantity. Further, with discussion pertaining to aspecific composition of matter, that description is by example only, anddoes not limit the applicability of other species of that composition,nor does it limit the applicability of other compositions unrelated tothe cited composition.

What will be shown and described herein, along with various embodimentsof the present invention, is discussion of one or more simulations thatwere performed. It is understood that such examples are by way ofexample only, and are not to be construed as being limitations on anyembodiment of the present invention. Further, it is understood thatembodiments of the present invention are not necessarily limited to ordescribed by the mathematical analysis presented herein.

Various references may be made to one or more processes, algorithms,operational methods, or logic, accompanied by a diagram showing suchorganized in a particular sequence. It is understood that the order ofsuch a sequence is by example only, and is not intended to be limitingon any embodiment of the invention.

What will be shown and described herein are one or more functionalrelationships among variables. Specific nomenclature for the variablesmay be provided, although some relationships may include variables thatwill be recognized by persons of ordinary skill in the art for theirmeaning. For example, “t” could be representative of temperature ortime, as would be readily apparent by their usage. However, it isfurther recognized that such functional relationships can be expressedin a variety of equivalents using standard techniques of mathematicalanalysis (for instance, the relationship F=ma is equivalent to therelationship F/a=m). Further, in those embodiments in which functionalrelationships are implemented in an algorithm or computer software, itis understood that an algorithm-implemented variable can correspond to avariable shown herein, with this correspondence including a scalingfactor, control system gain, noise filter, or the like.

Various embodiments of the present invention include the application ofsteam/CO2 reforming technology which can accept small bags of waste, insome cases similar to what common residences generate in kitchens anddispose in garbage cans around the world. Garbage bags similar to thisare being generated by the FOBs as well. For medical facilities thebiotoxic and pathogen waste also can be disposed with this technologylocally in secure medical facilities while avoiding the dangeroustransportation to landfills or worse to medical incinerators. However,various embodiments contemplate the use of any type of organic materialprovided in any manner.

Various embodiments of the present invention include a rotary ovenreformer (ROR) that provides a small and convenient access point forreceiving the bags of garbage or medical waste, an efficient scheme forprocessing this material, and a scheme for extracting the metals andglass capable of recycle.

In FIG. 1 is shown the rotary oven reformer (ROR) that would have acapacity of about 500 pounds per day of waste/biomass feedstock, whichcan include a moisture content around 50%. A small amount of limestoneis preferably added to assist the removal of acid gases. One way thewaste could be fed in would be by use of plastic garbage bags with themaximum diameter of 18 inches, like used in a common residentialkitchen. The ROR would take about 10 to 20 of these bags. The front door(42,62) shown in FIG. 2 would be closed against seal 18 and the RORwould be sealed with a slight negative pressure of 2 to 5 inches ofwater and processing started.

Now referring back to FIG. 1 , the interior of the ROR 2 is heated bysuperheated steam and CO₂ shown entering 22 thru the center heatingcartridge 24, as well as by a by a plurality of heating rods 34 on theexterior. The ROR drum 12 is set into rotary motion in a clockwisedirection at a few RPM. The plastic bags that are placed through thefront opening 32 are tumbled by rotating on tires rollers 16 against theouter surface of the drum, such that the bags come into contact againstspiral vanes 14 with sharp edges or teeth which break open these bagsand disperse the waste/biomass contents and contact it with the hotsuperheated steam and CO₂.

As the process begins, the temperature of the ROR ramps from roomtemperature up to 900° F. at the end of the cycle but with thesuperheated steam and CO₂ entering the ROR at 1200 to 1800° F. Thereforming chemistry prepares high H₂ syngas. This syngas containing someparticulates is pulled out through the outside of the center heatingcartridge through a centered metal filter sock 26, which is removablefor cleaning. This non-rotating center heating cartridge 24 is glowingyellow orange at about 1400 to 1900° F., with its temperature radiatingonto the tumbling waste/biomass. The outside of the ROR is heated byelectric heating elements 34 about preferably 4 feet long and preferablyfixed in place. In some embodiments only the drum is rotating, using acenter heating cartridge 24 that preferably does not rotate and isgas-fed by a concentric rotating gas seal between the rotating drum andnon-rotating heating element apparatus.

After a period of operation, and with the end of cycle temperature atits maximum for about an hour, the processing cycle is complete, whichis expected to last a total from 4 to 20 hours, at which point thecooling cycle begins. The cooling gas entering at gas port 28 can be drynitrogen or CO₂, as examples. Once below 300° F., the right hand door 62hanging from its own hinge 36 is opened with rotary seal 60, unlocked bylock handle 64, and the left-hand door (attached by its own, separatehinge 36) is closed by handle 38, as best seen in FIG. 2 .

FIG. 2 shows the door arrangement of one embodiment. FIG. 2 shows theleft-hand door 42 insulated by plate 46 hinged at 32 that contains aremoval device such as a scoop 50 and a hopper 48 for removing anysolids 30 that are smaller than about a half an inch through exit 52.With this scoop door closed, the drum rotation is set tocounter-clockwise with the spirals 14 raising the small particulatematerial via scoop 50 to the front and down the scoop 50 into a sealedbin on wheels. In one embodiment the drum can contain about 75 pounds ofsolid grey-color material consisting of broken glass sand carbonaceousgraphite, oxides, and salt and lime. Solid items such as cans and metallids that would not go through the scoop are found in the top spiral atthe door edge for manual removal. Purge and cooling gas continue to flowinto the enclosed rotary oven 2 through the gas inlets 40 at left and 54at right.

The spiral arrangement 14 of teeth 15 is schematically depicted in FIG.5 . FIG. 5 shows three adjacent teeth 15 having a triangular shape. Eachtooth 15 includes a sharp vertex V that is adapted and configured forpuncturing the waste bags, and otherwise penetrating and impaling thewaste material as it tumbles. The top view in FIG. 5 shows a view ofthree teeth as viewed orthogonally from their overall spiral shape. Thebottom view of FIG. 5 shows depicts the teeth more from an elevated viewrelative to the spiral shape 14, showing that the base of the teeth formthe spiral shape, and further that the body of the tooth (which isgenerally planar) is non-perpendicular to the inner diameter of theoven. When the oven rotates in one direction, the sharp vertices V ofthe teeth lead (i.e., are in front of) the bottom wall W that connectsto the inner diameter. With such rotation, the teeth are adapted andconfigured to impale the waste. For rotation in the opposite direction,the wall W of the teeth leads the teeth vertices V. Therefore, in thisopposite direction of rotation the teeth are not angled so as topenetrate the waste. However, the spiral shaped wall W provides a ledgethat pushes against the waste. This ledge, in combination with thespiral shape, pushes the waste material toward the end of the ovenhaving the doors.

FIG. 3 shows a cross-section of the appliance which is about 7 feet wide6 feet deep and 7 feet tall in one embodiment. The ROR drum 12 is at thetop of this cross-section. At the front right is the main steam/CO₂reforming reactor 72 used for cleanup to produce the syngas. This veryhot syngas is cooled by a heat exchanger 74 (in one embodiment a plateheat exchanger) next in line with the cool syngas going to the fuel-cell65, preferably located down at the bottom of the enclosure. The heatfrom this heat exchanger and the heat from the fuel-cell are used toheat the superheated steam and the CO₂ that is fed into the ROR 2 atinlet 22. These clean gases are passed into the catalytic converter 76which removes any carbon monoxide prior to being discharged outside. Thecool exit gas is passed to a getter/sorbent bed for capturing any acidgases and heavy metals before moving further into the process. Heat fromthe catalytic converters is also used to provide heat to superheatedsteam entering 21 and also heat the ROR 12. Exit gases are cleaned andcarbon oxidized to CO₂, leaving at exhaust pipe 80. Also at the bottomof this enclosure are the rotary vacuum pumps 94 and 96 and a batterybank 63 to supply start up heat and power and uninterruptible power 82for the controls, 66 and 68, as well as 70, the control screen. Dieselfuel supply at 88 is pumped to the fuel cell 65 for startup electricityand heat.

FIG. 4 shows the process flow diagram that graphically implements thedetails of the paragraphs above. FIG. 4 shows the same cross-section ofthe appliance but with the process schematic units and flow-streamslocated in cabinet 92. The steam and CO₂ 22 enters the heated cartridge24 at the top of this cross-section and enters the ROR 12 at gas port28. The biomass and/or waste evolve volatile gasses 25 and producescrude syngas 20.

At the front right is the main steam/CO₂ reforming reactor 72 used forfinal cleanup to produce the high purity syngas 73. This very hot syngas73 is cooled quickly by a plate heat exchanger 74. Next in line with thecool syngas 73 goes via connection 75 to the catalytic converter 76 viaheat exchanger outlet 75 and then on to fuel-cell 65 down at the bottomof the enclosure. The heat 99 from this heat exchanger 74 and the heat94 from the fuel-cell 65 are used to heat the waste in the ROR 12. Thecatalytic converter 76 heats the superheated steam 93 and the CO₂ thatis fed via 22 into

The ROR. The catalytic converter exit gas 77 is passed to a getter andsorbent bed 78 destroying any acid gases before they are vented. Aportion of these clean gases 79 are pulled into the pumps 94 and 96 viastream 80 and 83, respectively. Stream 80 is vented via 94 at ambientexhaust port 90 and stream is split into 83 and 82, the latter going tofuel cell 65. The other fraction 83 recycles via 97 to heated cartridge24 to enter ROR 12 via gas port 28. Heat from the catalytic convertersalso used to help heat the ROR. At the bottom of this enclosure arelocated the two rotary vacuum pumps 94 and 96, diesel fuel tank 88 tosupply fuel 89 via fuel pump 61 to the fuel cell 65 for startup and foruninterruptible power 98 for the controls.

FIG. 6 shows a portion of an FT reactor that includes a plurality ofcatalyst-coated finned tube assemblies 204 according to one embodimentof the present invention. Each finned tube assembly 204 comprises a pairof a concentrically-arranged inner tube 228 and outer tube 210. Eachouter tube includes a plurality of cooling fins 208 extending from thetube outward. The cooling fins 208 are coated with a catalyst that isadapted and configured to produce Fischer-Tropsch reaction products fromsynthesis gas.

As shown in Section AA of FIG. 6 , in one embodiment the fins arelongitudinally arranged and generally parallel down the length of thetube assembly. This linear arrangement surface is adapted and configuredto provide a large surface area for improved operation of the catalyst,as well as relatively free-flowing passageways or channels for thedownward movement of heavier FT products that form on the catalyticsurfaces. However, yet other embodiments of the present inventioninclude still other fin shapes, such as spiral shapes (coacting with theo.d. to form spiral channels) that extend along the length of the tubeassembly. Preferably, the cooling fins provide relatively littleobstruction to the gravity-induced, downward movement of the heavier FTliquid products. In some embodiments, each cooling fin provides asurface that extends along substantially the entire length of the tubeassembly 204, so that the fin itself is not ever a barrier to downwardmovement.

In one embodiment, each tube assembly 204 comprises a tube within atube. The outer tube 210 includes an opened end that operates as aninlet for cooling media. This opened end is coupled by way of a union toa flange of the reactor for structural support and sealing. Thedistal-most, closed end 212 of external tube 210 extends downward towardthe bottom of the reactor (as shown in FIG. 7 , proximate to the inlet275 for syngas (referring to FIG. 9 ).

The inner tube 228 provides for upward return of the media as it isheated from contact with the inner diameter of outer tube 210. The innertube 228 has an opened end 227 located near the distal-most closed end212. This opened end 227 provides an inlet for the heated media that hasflowed downward in the annular passageway 209 that is formed between theinner diameter of the outer tube and the outer diameter of the innertube 228. The opened end 222 of the inner tube 228 provides the heatedmedia to a collection reservoir, such as either the manifold 238 shownin FIG. 6 or the plenum 238′ shown in FIG. 7 .

An FT catalyst-coated finned tube 210 is inserted through reactor topflange 212 attached by means of a sanitary union 214 through which thetube can be removed. At the top of the finned tube 210, a cooling mediasupply manifold 237 provides the cool thermal fluid 216 that enters atthe side of the tee 218, then passing downward through the finned tube,boiling, and flowing upward through a center tube 228 to exit at the topas the hot two-phase vapor-liquid exits 222 to media return manifold238.

Referring to FIG. 6 , through the top flange 212 the fresh syngas 230enters a tube that runs downward nearly the length to the bottom of thereactor 232 introducing fresh syngas that fills the chamber around thefin tubes 210. A substantial fraction of the syngas reacts on thecatalyst 210 to produce FT liquid product and the spent syngas exits thereactor at port 234. Since the catalyst-coated fins get hot from theexothermic reactions of the syngas to form FT liquid, the heat isremoved by cooling water that enters as coolant 216 and leaves as steam222. Although water is shown as the example, other thermal fluids can beused. The connections to each of the fin tubes 210 are made through aflexible stainless steel tubing 236 to a circular tube ring 237surrounding the top of the reactor above the flange. The steam leaves attwo layers of tubing that constitutes a double steam manifold at thetop. This design in some embodiments allows individual fin tubes to beremoved and fresh ones reinstalled by connecting the flexible tubing 236to the entry tee 218. In this way the finned tubes can be cleaned andthe catalyst refreshed and recoated on the finned tubes and remountedinto the reactor.

FIG. 7 shows a large pressure vessel 232 and flange 212 at the topthrough which fin tubes 208 are hung. The reactor of FIG. 7 is similarto the reactor of FIG. 6 , except that in FIG. 7 the coolant supplypassage 209 is supplied with the low temperature cooling media by way ofa cooling media plenum 237′ that is created between flanges 212 and 248.All coolant supply passages are open to this volume between the flanges,which is provided with coolant by way of port 250. It can further beseen that all of the coolant return passages 228 are in fluidcommunication with the plenum chamber 238′ between flange 248 and dome246. Steam can be removed by way of coolant return port 260.

These tubes 210 have fins extending radially from tube 220 and coatedwith catalyst 210. These catalyst tubes 208 can be individually removedfrom the reactor by the following steps: The upper flange 248 isunbolted from the flanges 212, and raised upward which includes thesteam tubes 228. The next step is to loosen locking nut 214 by means ofits the outside diameter threads 244 using the appropriate spannerwrench which removes pressure on the sealing ledge 246 attached to theflange 248. At this point tube 220 containing catalyst fins 210 can beremoved from the top individually.

Now referring to FIG. 8 , both the top flange and the cross-section ofthe reactor are shown with the circular tube manifold 238 and themultiplicity of finned tubes 208. At three locations 120° apart there isshown the entry 230 and exit 234, syngas supply and discharge pipes asarranged. The circular manifold assembly 238 is fed by a large mainsupply of cooling water entering at 240 and the hot steam exiting at alarge tube 242.

Into vessel reactor vessel 232, shown in FIG. 8 , is fed freshconditioned and balanced syngas through port 252 and the spent syngasexits at port 254. Reaction of the syngas on catalyst fins 210 producesa FT liquid which falls to the bottom of reactor 232 and exits at port258 while the steam that is produced from the heat of the fin tube 208exits at the top of the steam dome of the vessel at port 260. An accessport 256 is provided for inspecting and cleaning the vessel.

Referring to FIG. 9 , there is shown a schematic representation of aprocess for converting syngas according to one embodiment of the presentinvention. The FT reactor 270 is fed with cool water in streams 272cooling the catalyst finned tubes. The cool water is pumped by pump 278and temperature controlled by heater 276 to assure that the water is afew degrees below its boiling point. The generated steam plus a smallamount of entrained water leaves in stream 292 to pass through a steamtrap 291 to remove as much entrained water as possible and from thereenters the electricity generating steam turbine 90 with its exhaustcooled by air cooler 288. From there the cool condensate water is passedto pump 278 to complete the water-steam cycle loop.

The syngas enters the bottom of the FT reactor via 274 where it isreacted on the catalytic surface of a plurality of finned tube heatexchanging assemblies 273 and passes upward in the reactor generatingthe FT liquid 279 which drains off of the increasingly warmer finnedtubes 273 countercurrent down to the bottom of the reactor and exits asstream 281 of crude FT liquid product.

It is understood that the catalyzing, finned tube heat exchanger 273 aresimilar to the finned tube assemblies 208 shown in FIGS. 6, 7, and 8 .The spent syngas leaves the top of the FT reactor as stream 285 to becooled by heat exchanger 282 using cool water from pump 278 entering itat 284 and leaving 286 to enter the temperature control heater 276. Thecool syngas together with some liquid condensate leaves the heatexchanger 282 via line 90 from which it enters the three-phase separator292 where the hydrocarbon leaves via stream 294 as nearly finished FTliquid product and the condensed water leaves as stream 298.

Various aspects of some embodiments of the present invention can bebetter understood by considering other examples. As one exampleconsiders a simple cylindrical reactor vessel that is 18″ ID and 72″tall with a volume of 20,400 in3 or 11.8 ft3 and has a height allocatedfor the catalyst option that is 40″ tall. In one embodiment, a finnedtube array as shown in FIG. 7 contains 112,500 in2 of catalyst coatedsurface. Such a design compares favorably to existing designs that havethe same catalyst volume but only 38,883 in2 of catalyst area. Thereactor design disclosed in FIGS. 6 and 7 can contain nearly three times(3×) more catalyst surface area. Further, since there is less wastedspace, the finned tubes can be extended 35% more in length to gainanother 35% of catalyst area to achieve four times (4×) the catalystarea.

Yet another example showing various aspects of some embodiments of thepresent invention pertains to the improved maintenance that can result.Too many times the catalyst becomes poisoned from contaminants in thesyngas and the catalyst should be replaced. A typical FT reactor shouldbe removed from the plant and completely opened to remove the catalystmaterials and structure, the vessel cleaned, reloaded with freshcatalyst and remounted in the FT process plant, catalyst reactivatedwith H₂ at high temperature at a cost of many weeks of shutdown. Thereactor design taught herein eliminates the costly labor hours and longshutdown times, since individual finned tubes can be pulled out andreplaced in the field, while still keeping the reactor inerted saving70% of the labor hours.

In addition, sometimes the catalyst develops hot spots and melts orheavy resin is formed that plugs off the FT liquid flowing down thefinned tube and forms excessive heavy paraffin wax. These failed finnedtubes can be identified by an IR displaying camera to reveal obstructedflow of steam product or cooling water, together with finned tubeinternal temperatures measured by its type K thermocouples. This singlefailed finned tube can be removed and replaced at huge savings and theFT plant restarted often while it is still warm, still inerted; reducingstart-up time.

Yet other aspects of some embodiments of the present invention can beunderstood by considering the scalability offered. Individual finnedtubes can be removed, and the vessel is easily scaled in diameter whereadditional tubes can be added or even interchanged. Also, the vessel canbe made larger as necessary and multiple tube holes can be plugged andlater filled with finned tubes adding capacity that is made possible bydebottlenecking the process. A further advantage is that individualtubes can have different lengths as well, adjusting the capacity of theFT reactor. And even further advantage with this design is that thereactor can be scaled in diameter and length without changing the designconcepts. For example, the reactor shown in Example 1 can have an ID of18 inches and a height of 72 inches, producing one barrel per day of FTliquids. A full-size reactor of 8 feet in diameter and 12 feet inheight, simply by scaling this design, is projected to produce 57barrels per day or 2400 gallons per day of FT liquids. This single FTreactor would be the appropriate size for a 25 ton per day machine thatwould ideally fit a typical dairy farm to serve all of their fuel needs.

The process shown and discussed with regards to FIG. 9 was the subjectof multiple computer simulations. The process diagram used for thesimulations is shown in FIG. 10 , the subject matter of FIG. 10 alsobeing shown in the three portions identified by dotted and wavy lines asFIGS. 11, 12, and 13 . The thermodynamic methods used in the simulationsare as follows in Table A:

TABLE A K-Value: APISOAVE Enthalpy: APISOAVE Density: STD Liquid 1 NBS81Liquid 1 ThC: NBS81 Liquid 1 Den: STD Surface Tension: Visc: HADDENLiquid 2 STEAM Liquid 2 ThC: STEAM Liquid 2 Den: STD Surface Tension:Visc: STEAM

Various simulation inputs, assumptions, and results can be seen in thefollowing Tables B through F.

TABLE B Flowrates Incipient Total Vapor Liquid 1 Liquid 2 TotalComponent Name lbmol/hr mol fra lbmol/hr lbmol/hr mole % K-Value 48:CARBON MONOXIDE 0 0 0 0 0 497.314 1: HYDROGEN 0 0 0 0 0 198.932 62:WATER 0 0 0 0 0 1.06274 49: CARBON DIOXIDE 0 0 0 0 0 163.37 65:ACETYLENE 0 0 0 0 0 108.63 40: BENZENE 0 0 0 0 0 1.46198 22: ETHYLENE 00 0 0 0 112.732 2: METHANE 0 0 0 0 0 307.179 3: ETHANE 0 0 0 0 0 79.14824: PROPANE 0 0 0 0 0 27.5122 6: N-BUTANE 0 0 0 0 0 10.1972 8: N-PENTANE0.173323 0.261321 0.173323 0 7.09909 3.68104 10: N-HEXANE 0.1734830.130238 0.173483 0 7.10563 1.83288 11: N-HEPTANE 0.173114 0.0660580.173114 0 7.09051 0.931641 12: N-OCTANE 0.172974 0.033167 0.172974 07.08478 0.468143 13: N-NONANE 0.172763 0.017081 0.172763 0 7.076140.241389 14: N-DECANE 0.172554 0.008744 0.172554 0 7.0676 0.123716 15:N-UNDECANE 0.172346 0.004707 0.172346 0 7.05906 0.066677 16: N-DODECANE0.172135 0.002515 0.172135 0 7.05045 0.035669 17: N-TRIDECANE 0.1716840.00135 0.171684 0 7.03198 0.019203 18: N-TETRADECANE 0.171769 0.0006960.171769 0 7.03542 0.009886 19: N-PENTADECANE 0.171234 0.000381 0.1712340 7.01352 0.005437 20: N-HEXADECANE 0.18253 0.000219 0.18253 0 7.476210.002923 21: N-HEPTADECANE 0.012029 9.151E−06 0.012029 0 0.4926950.001857 91: N-OCTADECANE 0.0000491 2.035E−08 0.0000491 0 0.0020110.001012 92: N-NONADECANE 5.241E−07  1.39E−10 5.241E−07 0 2.147E−050.000648 93: N-EICOSANE 1.554E−08  2.08E−12 1.554E−08 0 6.364E−070.000327 3208: N-NONACOSANE 0 0 0 0 4.025E−20 1.092E−06 2051: ISOBUTYL 00 0 0 0 0.954131 FORMATE 1245: SODIUM 0 0 0 0 0 CHLORIDE 46: NITROGEN1.442E−17 1.263E−15 1.442E−17 0 5.905E−16 213.816 47: OXYGEN 0 0 0 0 0562.113 1021: METHANOL 0.241399 0.429368 0.241399 0 9.88739 4.342592038: ISOBUTYL 0.108097 0.044147 0.108097 0 4.4275 0.997104 ALCOHOL 200:Biosolids 0 0 0 0 0 2.645E−05 Total 2.44148 1 2.44148 0 100

TABLE C Flowrates Incipient Total Vapor Liquid 1 Liquid 2 TotalComponent Name lb/hr mass fra lb/hr lb/hr mass % 48: CARBON MONOXIDE 0 00 0 0 1: HYDROGEN 0 0 0 0 0 62: WATER 0 0 0 0 0 49: CARBON DIOXIDE 0 0 00 0 65: ACETYLENE 0 0 0 0 0 40: BENZENE 0 0 0 0 0 22: ETHYLENE 0 0 0 0 02: METHANE 0 0 0 0 0 3: ETHANE 0 0 0 0 0 4: PROPANE 0 0 0 0 0 6:N-BUTANE 0 0 0 0 0 8: N-PENTANE 12.5046 0.301 12.5046 0 3.79384 10:N-HEXANE 14.9493 0.1792 14.9493 0 4.53557 11: N-HEPTANE 17.3456 0.1056817.3456 0 5.26259 12: N-OCTANE 19.7577 0.06049 19.7577 0 5.99441 13:N-NONANE 22.1568 0.03498 22.1568 0 6.72228 14: N-DECANE 24.5503 0.0198624.5503 0 7.44846 15: N-UNDECANE 26.938 0.011746 26.938 0 8.17287 16:N-DODECANE 29.3195 0.006839 29.3195 0 8.89541 17: N-TRIDECANE 31.65070.003975 31.6507 0 9.6027 18: N-TETRADECANE 34.0755 0.002203 34.0755 010.3384 19: N-PENTADECANE 36.3711 0.001293 36.3711 0 11.0348 20:N-HEXADECANE 41.3307 0.00079 41.3307 0 12.5396 21: N-HEPTADECANE 2.892480.000035 2.89248 0 0.877567 91: N-OCTADECANE 0.012495  8.27E−08 0.0124950 0.003791 92: N-NONADECANE 0.000141 5.959E−10 0.000141 0 0.0000427 93:N-EICOSANE  4.39E−06 9.381E−12  4.39E−06 0 1.332E−06 3208: N-NONACOSANE4.017E−19 0 4.017E−19 0 1.219E−19 2051: ISOBUTYL FORMATE 0 0 0 0 0 1245:SODIUM CHLORIDE 0 0 0 0 0 46: NITROGEN 4.038E−16 5.647E−16 4.038E−16 01.225E−16 47: OXYGEN 0 0 0 0 0 1021: METHANOL 7.7349 0.2197 7.7349 02.34674 2038: ISOBUTYL ALCOHOL 8.01245 0.05225 8.01245 0 2.43094 200:Biosolids 0 0 0 0 0 Total 329.602 1 329.602 0 100

TABLE D Flowrates Total Vapor Liquid 1 Liquid 2 Total Component Nameft3/hr ft3/hr ft3/hr ft3/hr volume % 48: CARBON MONOXIDE 0 0 0 0 0 1:HYDROGEN 0 0 0 0 0 62: WATER 0 0 0 0 0 49: CARBON DIOXIDE 0 0 0 0 0 65:ACETYLENE 0 0 0 0 0 40: BENZENE 0 0 0 0 0 22: ETHYLENE 0 0 0 0 0 2:METHANE 0 0 0 0 0 3: ETHANE 0 0 0 0 0 4: PROPANE 0 0 0 0 0 6: N-BUTANE 00 0 0 0 8: N-PENTANE 0.506225 0 0.506225 0 7.09909 10: N-HEXANE 0.5066910 0.506691 0 7.10563 11: N-HEPTANE 0.505613 0 0.505613 0 7.09051 12:N-OCTANE 0.505204 0 0.505204 0 7.08478 13: N-NONANE 0.504588 0 0.5045880 7.07614 14: N-DECANE 0.503979 0 0.503979 0 7.0676 15: N-UNDECANE0.50337 0 0.50337 0 7.05906 16: N-DODECANE 0.502756 0 0.502756 0 7.0504517: N-TRIDECANE 0.501439 0 0.501439 0 7.03198 18: N-TETRADECANE 0.5016850 0.501685 0 7.03542 19: N-PENTADECANE 0.500123 0 0.500123 0 7.01352 20:N-HEXADECANE 0.533117 0 0.533117 0 7.47621 21: N-HEPTADECANE 0.035133 00.035133 0 0.492695 91: N-OCTADECANE 0.000143 0 0.000143 0 0.002011 92:N-NONADECANE 1.531E−06 0 1.531E−06 0 2.147E−05 93: N-EICOSANE 4.538E−080 4.538E−08 0 6.364E−07 3208: N-NONACOSANE 0 0 0 0 4.025E−20 2051:ISOBUTYL FORMATE 0 0 0 0 0 1245: SODIUM CHLORIDE 0 0 0 0 0 46: NITROGEN4.211E−17 0 4.211E−17 0 5.905E−16 47: OXYGEN 0 0 0 0 0 1021: METHANOL0.705054 0 0.705054 0 9.88739 2038: ISOBUTYL ALCOHOL 0.315718 0 0.3157180 4.4275 200: Biosolids 0 0 0 0 0 Total 7.13084 0 7.13084 0 100

TABLE E Flowrates Total Vapor Liquid 1 Liquid 2 Total Component NameSCF/hr SCF/hr SCF/hr SCF/hr std vol % 48: CARBON MONOXIDE 0 0 0 0 0 1:HYDROGEN 0 0 0 0 0 62: WATER 0 0 0 0 0 49: CARBON DIOXIDE 0 0 0 0 0 65:ACETYLENE 0 0 0 0 0 40: BENZENE 0 0 0 0 0 22: ETHYLENE 0 0 0 0 0 2:METHANE 0 0 0 0 0 3: ETHANE 0 0 0 0 0 4: PROPANE 0 0 0 0 0 6: N-BUTANE 00 0 0 0 8: N-PENTANE 0.317706 0 0.317706 0 4.46357 10: N-HEXANE 0.3609950 0.360995 0 5.07175 11: N-HEPTANE 0.40415 0 0.40415 0 5.67805 12:N-OCTANE 0.448128 0 0.448128 0 6.2959 13: N-NONANE 0.492178 0 0.492178 06.91478 14: N-DECANE 0.536288 0 0.536288 0 7.5345 15: N-UNDECANE 0.580590 0.58059 0 8.15691 16: N-DODECANE 0.623602 0 0.623602 0 8.76121 17:N-TRIDECANE 0.665575 0 0.665575 0 9.35091 18: N-TETRADECANE 0.711826 00.711826 0 10.0007 19: N-PENTADECANE 0.753102 0 0.753102 0 10.5806 20:N-HEXADECANE 0.849147 0 0.849147 0 11.93 21: N-HEPTADECANE 0.059015 00.059015 0 0.829129 91: N-OCTADECANE 0.000256 0 0.000256 0 0.003595 92:N-NONADECANE 2.875E−06 0 2.875E−06 0 4.039E−05 93: N-EICOSANE 8.915E−080 8.915E−08 0 1.253E−06 3208: N-NONACOSANE 0 0 0 0  1.12E−19 2051:ISOBUTYL FORMATE 0 0 0 0 0 1245: SODIUM CHLORIDE 0 0 0 0 0 46: NITROGEN8.025E−18 0 8.025E−18 0 1.127E−16 47: OXYGEN 0 0 0 0 0 1021: METHANOL0.15516 0 0.15516 0 2.1799 2038: ISOBUTYL ALCOHOL 0.160043 0 0.160043 02.2485 200: Biosolids 0 0 0 0 0 Total 7.11776 0 7.11776 0 100

TABLE F Properties Temperature F. 65° Pressure psia 38 Enthalpy Btu/hr−49154.95 Entropy Btu/hr/R −48.94892 Vapor Fraction 0 Total Liquid 1Flowrate lbmol/hr 2.4415 2.4415 Flowrate lb/hr 329.6023 329.6023 MoleFraction 1 1 Mass Fraction 1 1 Molecular Weight 135.0009 135.0009Enthalpy Btu/lbmol −20133.243 −20133.243 Enthalpy Btu/lb −149.1341−149.1341 Entropy Btu/Ibmol/R −20.0489 −20.0489 Entropy Btu/lb/R−0.148509 −0.148509 Cp Btu/lbmol/R 70.4007 Cp Btu/lb/R 0.5215 CvBtu/lbmol/R 62.859 Cv Btu/lb/R 0.4656 Cp/Cv 1.12 Density lb/ft3 46.2221Z−Factor 0.019714 Flowrate (T-P) gal/min 0.889097 Flowrate (STP) gal/min0.887409 Specific Gravity GPA STP 0.742497 Viscosity cP 0.630051 ThermalConductivity Btu/hr/ft/R 0.069657 Surface Tension dyne/cm 23.2852Critical Temperature (Cubic EOS) F. 689.9811° Critical Pressure (CubicEOS) psia 446.2985 Dew Point Temperature F. 500.9092° Bubble PointTemperature F. −405.4502° Water Dew Point Temperature could not becalculated Stream Vapor Pressure psia 1.319 Latent Heat of Vaporization(No Sensible Heat) Btu/lb 115.7845 Latent Heat of Vaporization (PlusSensible Heat) Btu/lb 381.5861 CO2 Freeze Up No Heating Value (gross)Btu/SCF 2497.73 Heating Value (net) Btu/SCF 2391.69 Wobbe Number Btu/SCF1060.98 Average Hydrogen Atoms 20.636 Average Carbon Atoms 9.318Hydrogen to Carbon Ratio 2.2146

Various aspects of different embodiments of the present invention areexpressed in paragraphs X1, X2, X3, and X4 as follows:

X1. One aspect of the present invention pertains to a method forconverting synthesis gas into Fischer-Tropsch products. One aspect ofthe present invention pertains to a method for providing a reactorvessel having a length with a plurality of tubular heat exchangingassemblies, each heat exchanging assembly having a length, the vesseland the heat exchanging assemblies being lengthwise parallel to eachother. One aspect of the present invention pertains to a method forflowing synthesis gas in one direction into the vessel, andcatalytically converting the flowing synthesis gas into Fischer-Tropschproducts and heat. One aspect of the present invention pertains to amethod for removing the heat by flowing a heat transfer media in theopposite direction in each tubular heat exchanging assembly.

X2. Another aspect of the present invention pertains to a heat transferassembly. The assembly includes an outer tube having an opened end and aclosed end, the outer diameter of said outer tube being at leastpartially coated in a catalyst. One aspect of the present inventionpertains to the assembly including a second inner tube located at leastin part in the interior of said outer tube and having two opened ends, afirst opened end being located proximate the closed end of said outertube, the second opened end being located proximate the opened end ofsaid outer tube. One aspect of the present invention pertains to anassembly wherein said outer and inner tubes coact to provide a flowpathfor a heat transferring media that extends from the opened end of saidouter tube to the first end of inner tube and then to the second end ofsaid inner tube.

X3. Yet another aspect of the present invention pertains to an apparatusfor calcination of organic material. One aspect of the present inventionpertains to an apparatus including a kiln rotatable about an axis, theinterior of said kiln including an array of teeth arranged in a row thatextends in a spiral shape relative to the axis, one end of said kilnincluding a hinged door having a waste removal aperture. One aspect ofthe present invention pertains to an apparatus including an electricheater placed within the interior of said kiln; wherein said array ofteeth are adapted and configured such that rotation of said kiln aboutthe axis in one direction provides a cutting action of said array ofteeth on the organic material, and rotation of said kiln in the oppositedirection provides by said array of teeth the movement of materialwithin said kiln toward said door.

X4. Still another aspect of the present invention pertains to a methodfor oxidation-reduction of organic material. One aspect of the presentinvention pertains to a method for providing a rotary kiln having aninternal spiral member, a door and an internal electric heater. Oneaspect of the present invention pertains to a method for breaking apartany organic material within the enclosed kiln by rotating said kiln in afirst direction. One aspect of the present invention pertains to amethod for heating the material within the kiln with the electricheater. Another aspect of the present invention pertains to moving thewaste material within the cooled kiln toward the door by rotating thekiln in the opposite direction. Still different embodiments of thismethod pertain to calcinating organic material, whereas otherembodiments pertain to methods for burning organic material.

Yet other embodiments pertain to any of the previous statements X1, X2,X3, or X4, which are combined with one or more of the following otheraspects. It is also understood that any of the aforementioned Xparagraphs include listings of individual features that can be combinedwith individual features of other X paragraphs.

Which further comprises a process for producing synthesis gas usingeither of the designs expressed in paragraphs X1 or X2, combined withone of the designs expressed in paragraphs X3 or X4.

Which further comprises flowing the heat transfer media from the bottomend of each tubular heat exchanging assembly toward the top end in asecond internal flowpath within each tubular heat exchanging assembly.

Which further comprises cooling the removed gaseous FT products byheating the media, and using the heated media during said flowing a heattransfer media.

Which further comprises adding heat to the heated media before saidflowing a heat transfer media.

Wherein said providing includes a heat engine coupled to an electricalgenerator, which further comprises powering said engine with the removedheat.

Wherein said outer tube and said inner tube are substantially linearbetween respective ends.

Wherein the opened end of said outer tube is adapted and configured tosupport said heat transfer assembly from a flange.

Which further comprises a plurality of heat transferring fins each atleast partially coated with the catalyst.

Wherein said fins are axial fins arranged generally parallel to thecenterline of each said tube.

Wherein said fin is arranged to form a substantially unobstructed drippath for the movement of liquid FT products along said fin and towardthe closed end.

Wherein said fin has a spiral shape along the length of said outer tube.

Wherein said fin and the outer diameter of said outer tube coact tocreate a channel for the downward flow of FT liquids.

Which further comprises a first fluid manifold in fluid communicationwith the opened end of said outer tube and a second fluid manifold influid communication with the second opened end of said inner tube.

Which further comprises a plurality of parallel, spaced-apart said heattransfer assemblies each supported at the opened end of the outer tubeby a flange and each adapted and configured both to be repeatedlyremoved separately from said flange and to be repeatedly installedseparately to said flange.

Wherein the opened end of each said outer tube are in fluidcommunication with one another and the second end of each said innertube are in fluid communication with one another.

Wherein said kiln is tapered about a length along the axis, and one endis smaller than the other end.

Wherein said door is a first hinged door, and which further comprises asecond hinged door located at the one end, said second door beingadapted and configured to seal an opening of said kiln during hightemperature operation.

Wherein each said tooth has at least one of a sawtooth or triangularoverall shape.

Wherein said teeth are arranged side-by-side, with the bottom ofadjacent teeth forming a spiral-shaped passageway for movement of wastematerial falling against the teeth during rotation of the kiln.

Wherein each said tooth is non-perpendicular to the inner wall of thekiln.

Wherein the row of teeth are arranged to lean in a direction adapted andconfigured to impale the rotating organic material.

Wherein said kiln has a rotating outer surface, which further comprisesat least one heating element located to heat said kiln through the outersurface.

Which further comprises a scoop adapted and configured to receivematerial from the kiln during rotation in the opposite direction andprovide the material to said aperture.

Which further comprises a ceramic filtering element placed around theexterior of said heater;

Which further comprises cooling the kiln after said synthesizing andbefore said removing.

Wherein the door includes hopper and said rotating in the oppositedirections places the waste material into the hopper.

Wherein the internal spiral member includes a plurality of teeth, andsaid breaking apart is by the teeth.

Wherein said rotating in a first direction moves the organic materialaway from the door.

Which further comprises injecting steam into said kiln during saidheating.

While the inventions have been illustrated and described in detail inthe drawings and foregoing description, the same is to be considered asillustrative and not restrictive in character, it being understood thatonly certain embodiments have been shown and described and that allchanges and modifications that come within the spirit of the inventionare desired to be protected.

What is claimed is:
 1. A heat transfer assembly for a Fischer-Tropschreactor, comprising: an outer tube having an opened end and a closedend, the outer diameter of said outer tube including at least one heattransferring fin, the fin being at least partially coated in a catalystuseful to produce Fischer-Tropsch products from synthesis gas in areactor; a second inner tube located at least in part in the interior ofsaid outer tube and having two opened ends, a first opened end beinglocated proximate the closed end of said outer tube, the second openedend being located proximate the opened end of said outer tube; whereinsaid outer and inner tubes coact to provide a flowpath for a heattransferring media that extends from the opened end of said outer tubeto the first end of inner tube and then to the second end of said innertube.
 2. The assembly of claim 1 wherein said outer tube and said innertube are substantially linear between respective ends.
 3. The assemblyof claim 1 wherein the opened end of said outer tube is adapted andconfigured to support said heat transfer assembly from a flange.
 4. Theassembly of claim 1 which further comprises a plurality of heattransferring fins each at least partially coated with the catalyst. 5.The assembly of claim 4 wherein said fins are axial fins arrangedgenerally parallel to the centerline of each said tube.
 6. The assemblyof claim 1 wherein said fin is arranged to form a substantiallyunobstructed drip path for the movement of liquid FT products along saidfin and toward the closed end.
 7. The assembly of claim 6 wherein saidfin has a spiral shape along the length of said outer tube.
 8. Theassembly of claim 1 wherein said fin and the outer diameter of saidouter tube coact to create a channel for the downward flow of FTliquids.
 9. The assembly of claim 1 which further comprises a firstfluid manifold in fluid communication with the opened end of said outertube and a second fluid manifold in fluid communication with the secondopened end of said inner tube.
 10. The assembly of claim 1 which furthercomprises a plurality of parallel, spaced-apart said heat transferassemblies each supported at the opened end of the outer tube by aflange and each adapted and configured both to be repeatedly removedseparately from said flange and to be repeatedly installed separately tosaid flange.
 11. The assembly of claim 10 wherein the opened end of eachsaid outer tube are in fluid communication with one another and thesecond end of each said inner tube are in fluid communication with oneanother.